Durango, 2001-2005

Starter

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Removal & Installation



3.7L & 4.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    NOTE
    If equipped with 4WD and certain transmissions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt.

  2.  
  3. Remove or disconnect the following:
    NOTE
    The left side exhaust pipe and front driveshaft must be disconnected.



    Negative battery cable
     
    Starter mounting bolts
     



    Starter solenoid harness connections
     
    Starter

    Click image to see an enlarged view

    Fig. Starter mounting, 3.7L and 4.7L engines. (1) battery positive cable, (2) nut, (3) starter mounting bolts, (4) starter, (5) wiring harness

    Starter mounting, 3.7L and 4.7L engines. (1) battery positive cable, (2) nut, (3) starter mounting bolts, (4) starter, (5) wiring harness
     

  4.  

To install:

  1. Connect the starter solenoid wiring connectors.
  2.  
  3. Install the starter and torque the bolts to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the negative battery cable and check for proper operation.
  6.  

5.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Depending on drivetrain configuration, a support bracket may be used.



    Negative battery cable
     



    Starter mounting bolts
     
    Starter solenoid harness connections
     
    Starter
     

  4.  

To install:

  1. Connect the starter solenoid wiring connectors.
  2.  
  3. Install the starter and torque the bolts to 50 ft. lbs. (68 Nm).
  4.  
  5. Install the negative battery cable and check for proper operation.
  6.  

5.9L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Starter mounting bolts
     
    Starter solenoid harness connections
     
    Starter
     

  4.  

To install:

  1. Connect the starter solenoid wiring connectors.
  2.  
  3. Install the starter and tighten the bolts to 50 ft. lbs. (68 Nm).
  4.  
  5. Install the negative battery cable and check for proper operation.
  6.  

Solenoid or Relay




NOTE
The starter solenoid is serviced with the starter motor.

The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC cover for relay identification and location. The starter relay cannot be repaired or adjusted; if faulty or damaged, it must be replaced.

  1. Disconnect negative battery cable.
  2.  
  3. Remove cover from Power Distribution Center (PDC) for relay identification and location.
  4.  
  5. Remove starter relay from PDC.
  6.  
  7. Installation is the reverse of removal.
  8.  

Testing & Troubleshooting



Correct starter motor operation can be confirmed by performing following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to Starting Specifications for starter motor specifications.

  1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation.
  2.  
  3. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on mounting flange of starter motor. Never clamp on starter motor by field frame.
  4.  
  5. Connect suitable volt-ampere tester and 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used.
  6.  
  7. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly.
  8.  
  9. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Starting Specifications for starter motor free running test voltage specifications.
  10.  
  11. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Starting Specifications section for starter motor free running test maximum amperage draw specifications.
  12.  

If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly.

 
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